Apparatus and method for aseptically filling pharmaceutical containers with a pharmaceutical fluid using rotary stage

ABSTRACT

Systems and methods for aseptically filling pharmaceutical containers with pharmaceutical fluid are disclosed. In one general aspect, these are based on an aseptically sealable chamber that includes a transfer wall to which pre-sealed pharmaceutical source and receiving containers are mounted aseptically. A robotic arm and a syringe store are disposed within the chamber along with a sterilizing facility for establishing in the chamber an aseptic condition. The robotic arm can grip and operate syringes to inject and/or extract pharmaceutical products from the containers by piercing their closures with the needles of the syringes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 15/453,615,filed Mar. 8, 2017; which application claims priority to U.S.Provisional Patent Application Ser. No. 62/371,196, filed Aug. 4, 2016;the disclosures of which are incorporated by reference in thisapplication in their entirety.

BACKGROUND OF THE INVENTION Field of the Invention

This present invention relates to the medical field and moreparticularly to apparatus and associated methods for sterilization ofand sterile handling of pharmaceutical materials and containers forpharmaceuticals, including bringing pharmaceuticals into form foradministration to medical or veterinary patients. In one aspect, itrelates to the programmed and automatic operation of such apparatus.

Background

The subject of filling pharmaceuticals into pharmaceutical containers isa major aspect of the Pharmaceuticals Industry. The subject is heavilycontrolled by various governmental and official bodies in variouscountries. Technologically, the subject is a challenge in that thepharmaceutical products need to be filled into the containers under verystrict aseptic conditions. Very specific procedures are specified forthis task to a degree that makes the handling of pharmaceuticalsprofoundly different from the handling of any other industrial product,including specifically semiconductors, which also demand extreme andconsistent environmental conditions. Indeed, the parallels between thehandling of semiconductors in semiconductor “clean laboratories” and thehandling of pharmaceuticals in aseptic isolators are superficial. Theyshare the use of such “clean laboratories”, but there is no inherentaseptic requirement associated with semiconductor manufacture.

The filling of pharmaceutical containers with fluid pharmaceuticalsspecifically requires the aseptic handling of both the containers andthe fluid pharmaceutical itself. This leads to complex mechanisms andprocedures, many of which may be automated to one degree or another.Often, the production equipment for fluid pharmaceutical handling isbulky and expensive. This creates a problem for smaller operations,particularly in the small scale production and development environments.As the field has developed, the need for smaller, more compactequipment, particularly in the filling and dispensing of fluidpharmaceuticals has become evident.

The present invention addresses the need for compact small scale fillingand dispensing of fluid pharmaceuticals.

SUMMARY OF THE INVENTION

In one general aspect, the invention features a system for asepticallyfilling pharmaceutical containers with pharmaceutical fluid thatincludes an aseptically sealable chamber. The aseptically sealablechamber includes a transfer wall with openings that each provide asealing surface that is aseptically sealable to a container. A roboticarm is disposed within the sealable chamber and has a range of motionthat allows it to move a fluid transfer conduit to each of the openings.The system also includes a fluid transfer actuator to drive fluidthrough the fluid transfer conduit, a sterilizing facility forestablishing an aseptic condition within the sealable chamber, and acontroller. The controller includes three-dimensional arm control logicto move the fluid transfer conduit to a selected container that sealablypasses through one of the openings. It also includes fluid transferactuation logic to operate the fluid transfer actuator to transfer fluidbetween a fluid transfer vessel and the selected container.

In preferred embodiments, the fluid transfer conduit can be a syringeneedle mounted on a syringe that includes a body and a plunger, with thefluid transfer actuator being a linear actuator that moves the plungerrelative to the body. The system can further include at least onecontainer with a pierceable closure sealably passing through one of theopenings with the pierceable closure positioned inside the sealablechamber and with the three-dimensional arm control logic being operativeto cause the syringe needle to pierce the pierceable closure. Thethree-dimensional arm control logic and the fluid transfer actuationlogic can be operative to transfer fluids from one container to another.The system can further include a syringe store disposed in the interiorof the sealable chamber, with the three-dimensional arm control logicbeing operative to transfer syringes to and from the syringe store. Therobotic arm can be an articulated robotic arm. The sealable chamber canbe capable of being operated under a positive pressure when sealed.

In another general aspect, the invention features a method for fillingpharmaceutical containers with a fluid pharmaceutical product. Thismethod includes providing an aseptically sealable chamber comprising arobotic arm and a transfer wall capable of having aseptically mountedthereto a plurality of pharmaceutical containers pre-sealed withpierceable closures. The aseptically sealable chamber is capable ofmaintaining an aseptic condition within an interior of the sealablechamber when the pharmaceutical containers are mounted to the transferwall. The method also includes aseptically mounting to the transfer walla plurality of pharmaceutical containers aseptically pre-sealed withcorresponding pierceable pharmaceutical container closures, with themounting of the plurality of pharmaceutical containers comprisingmounting the plurality of pharmaceutical containers in locations andorientations wherein the corresponding pierceable pharmaceuticalcontainer closures are penetrable from within the interior of thesealable chamber. The sealable chamber is provided with a firstpharmaceutical syringe comprising a first syringe needle, the chamber isaseptically sealed, and an aseptic condition is established within theinterior of the sealable chamber and on all portions of the plurality ofpharmaceutical containers exposed to the interior of the sealablechamber. A portion of the first fluid pharmaceutical product can then betransferred between the first syringe and at least one of the pluralityof pharmaceutical containers through the corresponding pierceablepharmaceutical container closure via the first syringe needle.

In preferred embodiments the transferring can comprise piercing thecorresponding pierceable pharmaceutical container closure with the firstsyringe needle. The transferring can comprise operating the robotic arm.Providing an aseptically sealable chamber comprising a robotic arm cancomprise providing an aseptically sealable chamber comprising anarticulated robotic arm with the transferring comprising operating thearticulated robotic arm. The transferring can include injecting aportion of the first pharmaceutical product into the one of theplurality of pharmaceutical containers, and providing within thesealable chamber the first pharmaceutical syringe containing the firstfluid pharmaceutical product can comprise: aseptically mounting to thetransfer wall a first source pharmaceutical container asepticallypre-sealed with a corresponding pierceable first pharmaceuticalcontainer closure, with the mounting of the first source pharmaceuticalcontainer comprising disposing the first source pharmaceutical containerin a location and orientation wherein the first pharmaceutical containerclosure is penetrable from within the interior of the sealable chamber,piercing the closure of the first source pharmaceutical container withthe first syringe needle, and extracting a portion of the first fluidpharmaceutical product from the first source pharmaceutical containerinto the first pharmaceutical syringe. At least one of the asepticallysealing, the establishing an aseptic condition, the transferring, andthe extracting a portion of the first fluid pharmaceutical product canbe performed automatically. The method can further comprise establishingwithin the sealable chamber a positive atmospheric pressure. Theestablishing within the sealable chamber a positive atmospheric pressurecan be performed automatically after the aseptically sealing thesealable chamber. The method can further comprise injecting a portion ofa second fluid pharmaceutical product from a second syringe into the atleast one of the plurality of pharmaceutical containers through thecorresponding pierceable pharmaceutical container closure via a secondsyringe needle. The providing an aseptically sealable chamber cancomprise providing an aseptically sealable chamber comprising a syringestore, with the second syringe being prepared by: aseptically mountingto the transfer wall a second source pharmaceutical containeraseptically pre-sealed with a corresponding pierceable secondpharmaceutical container closure and containing the second fluidpharmaceutical, with the mounting of the second source pharmaceuticalcontainer comprising disposing the second source pharmaceuticalcontainer in a location and orientation wherein the secondpharmaceutical container closure is penetrable from within the interiorof the sealable chamber, operating the robotic arm to place the firstsyringe in the syringe store, operating the robotic arm to obtain fromthe syringe store the second pharmaceutical syringe comprising thesecond syringe needle, operating the robotic arm to pierce the closureof the second source pharmaceutical container with the second syringeneedle, and operating the robotic arm to extract a portion of the secondfluid pharmaceutical product from the second source pharmaceuticalcontainer into the syringe. The establishing an aseptic condition cancomprise treating the interior of the sealable chamber and all portionsof the at least one pharmaceutical container exposed to the interior ofthe sealable chamber with at least one of heated water vapor, gaseoushydrogen peroxide, ozone, nitrogen dioxide, ethylene oxide, andglutaraldehyde vapor.

In a further general aspect, the invention features a system foraseptically filling pharmaceutical containers with pharmaceutical fluidthat includes means for receiving a plurality of containers whileexposing accessible parts of the containers, means for transferringpharmaceutical fluid to and from the containers through the accessibleparts of the containers, and means for reaching the accessible parts ofthe received containers with the means for transferring. The system alsoincludes means for controlling the means for reaching and the means fortransferring, means for together isolating the exposed parts of thecontainers, the means for reaching, and the means for transferring, andmeans for sterilizing the exposed parts of the containers, the means forreaching, and the means for transferring.

Systems according to the invention can provide a compact andcost-effective way to automatically perform a wide variety ofpharmaceutical filling operations in an aseptic environment usingreadily available pre-sterilized containers with pierceable closures.

BRIEF DESCRIPTION OF THE DRAWINGS

The above mentioned and other features and objects of this invention,and the manner of attaining them, will become more apparent and theinvention itself will be better understood by reference to the followingdescription of an embodiment of the invention taken in conjunction withthe accompanying drawings, wherein:

FIG. 1 is a drawing of a first embodiment of an apparatus for fillingpharmaceutical containers with a pharmaceutical fluid product.

FIG. 2(a) is an exploded view of one example aseptic sealing structurefor sealing a pharmaceutical container to a transfer wall between anaseptic interior volume and an ambient volume of an apparatus foraseptically filling pharmaceutical containers with a pharmaceuticalfluid.

FIG. 2(b) is a view of the example aseptic sealing structure of FIG.2(a) when assembled.

FIG. 2(c) is a cross-sectional view of the assembled aseptic sealingstructure of FIG. 2(b)

FIG. 2(d) is a drawing of an arrangement for aseptically sealing aplurality of pharmaceutical containers to a sealing plate that may beaseptically sealable to a transfer wall between an aseptic interiorvolume and an ambient volume of an apparatus for aseptically fillingpharmaceutical containers with a pharmaceutical fluid.

FIG. 2(e) is a drawing of one example aseptic sealing structure forsealing a intra-venous bag pharmaceutical container to a transfer wallbetween an aseptic interior volume and an ambient volume of an apparatusfor aseptically filling pharmaceutical containers with a pharmaceuticalfluid.

FIG. 2(f) is a cross-sectional view of the structure of FIG. 2(e)

FIG. 2(g) is a drawing of an arrangement for aseptically sealing aplurality of intra-venous bag pharmaceutical containers to a sealingplate that may be aseptically sealable to a transfer wall between anaseptic interior volume and an ambient volume of an apparatus foraseptically filling pharmaceutical containers with a pharmaceuticalfluid.

FIG. 3 is a drawing of a second embodiment of an apparatus for fillingpharmaceutical containers with a pharmaceutical fluid product.

FIG. 4 is a flow diagram of a method for filling a pharmaceuticalcontainer with a fluid pharmaceutical product.

Corresponding reference characters indicate corresponding partsthroughout the several views. Although the drawings representembodiments of the present invention, the drawings are not necessarilyto scale and certain features may be exaggerated in order to betterillustrate and explain the present invention. The flow charts are alsorepresentative in nature, and actual embodiments of the invention mayinclude further features or steps not shown in the drawings. Theexemplifications set out herein illustrate embodiments of the invention,in one or more forms, and such exemplifications are not to be construedas limiting the scope of the invention in any manner.

DESCRIPTION OF EMBODIMENTS OF THE PRESENT INVENTION

The embodiments disclosed below are not intended to be exhaustive orlimit the invention to the precise form disclosed in the followingdetailed description. Rather, the embodiments are chosen and describedso that others skilled in the art may utilize their teachings.

The present invention relates to an apparatus and method for filingpharmaceutical containers with a pharmaceutical. In FIG. 1 , a fillingsystem 1000 comprises a container chamber 100 in communication with anambient environment and a sealable chamber 200 adjoining the containerchamber 100, the sealable chamber 200 being capable of having an asepticenvironment established within its interior and capable of maintainingthat aseptic environment within its interior. The communication ofchamber 100 with the ambient environment may be via a suitable accessdoor 102, schematically shown in broken outline in FIG. 1 . The ambientenvironment may be, for example, a clean room adapted for the handlingof pharmaceuticals during production.

Chamber 200 shares with chamber 100 a transfer wall 280 and comprises anaseptically sealable port 220. A variety of suitable port arrangementsis contemplated. In some embodiments, port 220 is a simple door with anaseptic seal arrangement to ensure that chamber 200 maintains an asepticcondition. In other embodiments, port 220 may be a more complex doorarrangement to ensure the aseptic condition in the interior of chamber200. In some embodiments, chamber 100 is completely open. This is theequivalent of there being no distinct first chamber 100.

The interior of sealable chamber 200 may be rendered aseptic by any oneor more of a number of treatments, including specifically treatmentswith sterilants, such as steam, hydrogen peroxide vapor, ozone, nitrogendioxide, and ethylene oxide. The structures and mechanisms to performsuch sterilization steps are well known in the art and, in the interestof clarity, are not shown in FIG. 1 .

The terms “aseptic” and “sterilize” and their derivatives are to beunderstood as follows for the purposes of the present specification.Establishing an aseptic condition in the interior of a chamber shall beunderstood to mean establishing that condition throughout the internalatmosphere of the chamber as well as on substantially all exposedinterior surfaces of the chamber. This shall include the surfaces of allitems, containers, subsystems and the like exposed to the interioratmosphere of the chamber. The degree of sterilization may in somepractical cases not be total. Extremely tight crevices or microcrevicesmay exist in the interior of the chamber, for example, such that asterilizing gas or vapor may not perfectly penetrate into such tightregions. This is acknowledged both in the industry and in the standardsset for industry.

As will be described below, some embodiments of the invention involvecontainers of which portions of their exterior surfaces are exposed tothe internal atmosphere of a chamber. When the interior of the chamberis being sterilized, the portion of the surface of the container that isexposed to the internal atmosphere of the chamber is sterilized in theprocess. The action of establishing an aseptic condition within theinterior of the chamber and “sterilizing the interior of the chamber”shall have the same meaning in this specification.

Introducing into the interior of a chamber with an aseptic condition anitem of which the surfaces are not suitably sterilized destroys theexisting aseptic condition within the chamber. Conversely, introducingan aseptic or sterilized item into an interior of a chamber that doesnot have an aseptic condition within that interior does not render thatinterior aseptic. In fact, all it does is to destroy the asepticcondition of the surface of the item so introduced. Similarly,introducing filtered air, even with all biological entities filteredout, into an unsterilized chamber does not in any way sterilize thechamber or render it aseptic to a degree acceptable in thepharmaceutical industry. The reason is that the interior surfaces of thechamber are not sterilized by the introduction of such air. All that isachieved is to contaminate the filtered air with active biologicalspecies resident on the interior surfaces of the unsterilized chamber.

In the interest of clarity and completeness, it should also be recordedthat in the art the term “aseptic” is also sometimes used in associationwith the introduction of pharmaceutical fluids along aseptic tubes intobodies within controlled chambers. In such cases the term in the artrefers to the condition inside the tube or to the fact that thepharmaceutical fluid may be filtered to a suitable degree. This in noway sterilizes or renders aseptic the interior of the chamber inquestion. The aseptic condition in such cases is confined to theinterior of the tube bearing the pharmaceutical stream. Such streams areoften filtered to a high degree, but such filtering affects only theinterior of the particular tube and does not in any way sterilize theinterior of the chamber.

In some prior art systems, containers introduced into a chamber for thepurposes of being filled with a pharmaceutical are routed throughsterilizing subsystems. This kills biological species on the containers.When such sterilized containers are introduced into the chamber when thechamber itself is not aseptic the containers lose their asepticcondition as biological species contained within the chamber willdeposit on the previously aseptic containers.

Standards for clean rooms exist from both the United States FederalGovernment and ISO (International Standards Organization). These specifyin great detail the allowed particulate content of a cubic volume of airin such a clean room facility. But none of these standards directlyaddress the matter of biological species present on surfaces in theroom. This serves to make the point that a chamber cannot be renderedaseptic by the management of its atmosphere or airflow only. Nor,conversely, can the chamber be rendered aseptic by the sterilization ofonly the surfaces of its interior. Rating a pharmaceutical orsemiconductor clean room at any quality level, therefore, including“Class 100”, “Class 10” or “Class 1”, even when employing laminar flowhoods and the like or any quality of HEPA (High Efficiency ParticulateAir) filters or ULPA (Ultra Low Particulate Air) filters, is notsufficient to assure an aseptic chamber at least because these standardsdo not provide for an assurable means to render the surfaces of the roomsterile or aseptic.

The text “Guideline for Disinfection and Sterilization in healthcareFacilities, 2008” by Rutala et al from the Center for Disease Controllists a compendium of mechanisms and methods for sterilization. Ourconcern in this specification is specifically with those mechanisms forsterilizing the interior of a chamber; that is, sterilizing both theinterior surfaces and the atmosphere within the chamber. Given therequirements, vapor base methods are most appropriate to the task. Theseinclude, but are not limited to, treatment with heated water vapor,hydrogen peroxide vapor, ozone, nitrogen dioxide, ethylene oxide,glutaraldehyde vapor or other suitable sterilizing gases and vapors. Inone suitable method appropriate to the present invention, thesterilization is by means of hydrogen peroxide vapor which is thenflushed using ozone before the chamber is employed in the filling ofpharmaceutical containers.

Sealable chamber 200 may comprise in its interior a robotic rotary arm260 mounted on a rotary stage 270. Rotary stage 270 may also be anextensible stage so that robotic arm 260 may be raised and loweredvertically. Robotic rotary arm 260 may comprise two grips 262 and 264disposed and configured for gripping a syringe 600 and for moving aplunger of the syringe 600 with respect to the cylinder of the syringe600. In FIG. 1 , grip 264 is disposed and configured to grip the plungermechanism of syringe 600 and to move it with respect to the cylinder ofsyringe 600, which is held stationary relative to robotic rotary arm 260by grip 262. By rotating rotary stage 270, raising or lowering rotarystage 270, and operating grip 264, the syringe 600 may therefore bepositioned anywhere on a cylindrical surface determined by a radius ofrobotic rotary arm 260 and the vertical adjustment range of rotary stage270, and the syringe 600 may be operated to perform an injectionprocedure or extraction procedure while so positioned. In otherembodiments, robotic rotary arm 260 may be extensible to thereby allowsyringe 600 to be positioned in a wider range of positions interior tothe cylindrical surface defined by the maximum extendible radius ofrobotic rotary arm 260. In the embodiment shown in FIG. 1 , robotic arm260 is specifically a non-articulated robotic arm. To the extent thatthe present invention seeks simplicity and compactness, there is norestriction for robotic arm 260 to specifically emulate the human arm inits articulation. Yet further robotic arm arrangements are contemplatedand will be discussed later below.

Sealable chamber 200 may further comprise in its interior a syringestore. In the embodiment shown in FIG. 1 , the syringe store is acarousel 230 mounted on a stage 232. Carousel 230 is configured forholding a plurality of syringes 600 having syringe caps 620. In someembodiments, stage 232 may be a vertically extensible stage bearingfurther carousels 230. In such embodiments, stage 232 may be disposedand configured to raise and lower the carousel 230. Carousel 230 isdisposed in a position that allows robotic rotary arm 260 to collect andreturn syringes 600 from and to carousel 230. To this end, carousel 230is a rotary carousel allowing different ones of syringes 600 to beaccessible to the grippers 262 and 264 of robotic rotary arm 260.

Sealable chamber 200 may further comprise in its interior a syringecapping station 250, disposed and arranged for robotic rotary arm 260 toengage syringes 600 with syringe capping station 250 to thereby removesyringe caps 620 from syringes 600 or to return syringe caps 620 tosyringes 600 after the use of syringes 600.

By way of example, rotary stage 270 may rotate arm 260 clockwise(looking down vertically in FIG. 1 ) in order to collect a syringe 600from carousel 230, while rotary stage 270 may rotate arm 260anti-clockwise (looking down vertically in FIG. 1 ) in order to engage asyringe 600 with capping station 250 in order to remove a cap 620 fromthe syringe 600 and thereby expose hollow syringe needle 610, forexample a hypodermic needle.

Robotic arm 260 may be controlled by controller 700 in communicationwith robotic arm 260. In FIG. 1 controller 700 is shown as a distinctseparate unit, but in other embodiments it may be incorporated intoeither chamber 100 or chamber 200. Controller 700 may comprise asuitable computer or microcontroller with memory to store a softwareprogram and data provided by the operator. The operating of robotic arm260 may comprise the operating of rotary stage 270 and the operating ofgrips 262 and 264. In some embodiments, controller 700 may also operatethe sterilization facility not shown in FIG. 1 . Controller 700 mayfurther control the rotation of carousel 230 and stage 232. Controller700 may also control the sealing of chamber 200 and the pressure insideof chamber 200. This allows the automation of the processes employed insystem 1000.

A variety of containers may be disposed within the interior of chamber100. In FIG. 1 the examples given are rigid pharmaceutical containers510 of a first size, rigid pharmaceutical containers 530 of a secondsize, and intravenous (IV) bags 550, being sealed to the transfer wall280 by container sealing structures 520, 540 and 560 respectively.Transfer wall 280 may have corresponding holes to allow access by needle610 to the various containers while an aseptic condition is maintainedin the interior of chamber 200.

In FIG. 1 container sealing structures 520, 540 and 560 are merelyschematically indicated. FIGS. 2(a), (b) and (c) show an exploded view,assembled view, and cross-section respectively of one example asepticsealing structure 520 by which container 510, for example, may beaseptically sealed to transfer wall 280 in order to give the needle 610of syringe 600 access to the interior of the aseptically sealedcontainer 510 without compromising the aseptic condition maintained inthe interior of sealable chamber 200. Sealing structure 540 may comprisea differently sized arrangement of the same design to seal container 530to transfer wall 280. In FIG. 1 two sizes of rigid pharmaceuticalcontainers are shown. In general, fewer or more containers may beemployed in chamber 100.

In one example, shown in FIG. 2(a), sealing structure 520 comprisesflange structure 522 having a recessed portion with vapor communicationholes 523. Container 510, aseptically sealed with a compressiblepierceable closure 512, for example a thermoplastic stopper, is placedupside down into the recessed portion of flange 522 with pierceableclosure 512 over hole 521. Cap 524 may then be placed over the upwardfacing bottom of the container 510 and tightened down onto flange 522 bymeans of bolts 526. FIG. 2(b) is an isometric view of the completedarrangement of container 510 with closure 512 mounted in sealingstructure 520. FIG. 2(c) shows how container 510 is sealed asepticallyto sealing structure 520 by means of o-rings 525 and the compressiblepierceable closure 512. Sealing structure may be aseptically sealed totransfer wall 280, for example using o-rings 528 and suitable bolts (notshown).

When flange 522 is mounted to transfer wall 280, the recessed portion offlange 522 extends into the interior of chamber 200. Any gas or vaporemployed to sterilize the interior of sealable chamber 200 may movethrough holes 523 in order to sterilize any portion of the exteriorsurface of container 510 that is accessible to sterilizing vapor or gasemployed in the interior of sealable chamber 200. In this specificationthe phrase “sterilizable portion” is used to describe that portion ofthe exterior surface of a pharmaceutical container aseptically sealed tothe transfer wall 280 that is accessible to sterilizing vapor or gasemployed to establish an aseptic condition in the interior of sealablechamber 200.

With flange 522 mounted to transfer wall 280, robotic rotary arm 260 mayposition and manipulate syringe 600 in order to pierce the pierceableclosure 512 through hole 521 with hollow needle 610. With the needlewithin the interior volume of container 512, a portion of any fluid insyringe 600 may be injected into container 510, or a portion of anyfluid in container 512 may be extracted from container 510 into syringe600 for use elsewhere.

FIG. 2(d) shows a container mounting plate 570 to which a plurality ofcontainer sealing structures 520 may be aseptically sealed in the sameway, described above, as used to seal sealing structure 520 to transferwall 280. In this particular embodiment, plate 570 is aseptically sealedto transfer wall 280 by means of, for example without limitation,suitable o-rings and bolts (not shown). Transfer wall 280 may havecorresponding holes to accommodate the plurality of pierceable closures512 and flanges 522.

One particularly useful type of pharmaceutical container is theintra-venous bag (IV-bag). FIG. 2(e) and FIG. 2(f) are isometric andcross-sectional views respectively of an example sealing structure 560for the aseptic sealing of an IV-bag container 550 to transfer wall 280.IV-bag tube 552 is aseptically sealed with pierceable closure 554.Pierceable closure 554 may be aseptically sealed to flange 562 by meansof o-ring 565. Two half-annular caps 564 hold pierceable closure 554 toflange 562 by means of bolts 566. Sealing structure 560 may beaseptically sealed to transfer wall 280 by means of o-ring 568 and bolts(not shown).

FIG. 2(g) shows a container mounting plate 580 to which a plurality ofcontainer sealing structures 560 may be aseptically sealed in the sameway, described above, as used to seal sealing structure 560 to transferwall 280. In this particular embodiment, plate 580 is aseptically sealedto transfer wall 280 by means of, for example without limitation,suitable o-rings and bolts (not shown). Transfer wall 280 may havecorresponding holes to accommodate the plurality of pierceable closures554 and flanges 562.

In embodiments where chamber 200 is absent, the fact that the inventionallows for the pharmaceutical containers 510, 530, 550 to be mounted totransfer wall 480 under ambient conditions becomes particularly evident.

To ensure that atmosphere external to chamber 200 cannot leak intochamber 200, chamber 200 is capable of operating under a positivepressure with respect to the environment outside chamber 200. This aidsin ensuring the aseptic condition inside chamber 200.

A further embodiment of the apparatus of the invention is shown in andFIG. 3 in which a filling system 2000 comprises a first chamber 300 incommunication with an ambient environment and a second sealable chamber400 adjoining the first chamber 300, the second chamber 400 beingcapable of having an aseptic environment established within its interiorand capable of maintaining that aseptic environment within its interior.The communication of chamber 300 with the ambient environment may be viaa suitable access door 302, schematically shown in broken outline inFIG. 3 . The ambient environment may be, for example, a clean roomadapted for the handling of pharmaceuticals during production.

Chamber 400 shares with chamber 300 a transfer wall 480 and comprises anaseptically sealable port 420. A variety of suitable port arrangementsis contemplated. In some embodiments, port 420 is a simple door with anaseptic seal arrangement to ensure that chamber 400 maintains an asepticcondition. In other embodiments, port 420 may be a more complex doorarrangement to ensure the aseptic condition in the interior of chamber400. In some embodiments, chamber 300 is completely open. This is theequivalent of there being no distinct first chamber 300. This emphasizesthe point that the invention allows for the pharmaceutical containers510, 530, 550 to be mounted to transfer wall 480 under ambientconditions.

The interior of chamber 400 may be rendered aseptic by any one or moreof a number of treatments, including specifically treatment with steam,hydrogen peroxide vapor, ozone, nitrogen dioxide, and ethylene oxide.The structures and mechanisms to perform such sterilization steps arewell known in the art and, in the interest of clarity, are not shown inFIG. 3 .

Chamber 400 may comprise in its interior a robotic arm 460 mounted on arotary stage 470. Rotary stage 470 may also be an extensible stage sothat robotic arm 460 may be raised and lowered vertically. Robotic arm460 may be an articulated robotic arm comprising first 466 and second468 arms that articulate with respect to each other about a commonrotary elbow 469. Robotic arm 460 may comprise two grips 462 and 464disposed and configured for gripping a syringe 600 and for moving aplunger of the syringe 600 with respect to the cylinder of the syringe600. In FIG. 3 , grip 464 is disposed and configured to grip the plungermechanism of syringe 600 and to move it with respect to the cylinder ofsyringe 600, which is held stationary relative to arm 468 by grip 462.By rotating rotary stage 470, raising or lowering rotary stage 470,articulating robotic arm 460, and operating grip 264, the syringe 600may therefore be positioned over a wide range of positions in theinterior of chamber 400, and the syringe 600 may be operated to performan injection procedure or extraction procedure while so positioned.

Chamber 400 may further comprise in its interior a syringe store 430 forholding a plurality of syringes 600 having syringe caps 620. Syringestore 430 is disposed in a position that allows robotic arm 460 tocollect and return syringes 600 from and to syringe store 430.

Chamber 400 may further comprise in its interior a syringe cappingstation 450, disposed and arranged for robotic rotary arm 460 to engagesyringes 600 with syringe capping station 450 to thereby remove caps 620from syringes 600 to thereby expose hollow syringe needle 610, forexample a hypodermic needle, or to return caps 620 to syringes 600 afterthe use of syringes 600.

Robotic arm 460 may be controlled by controller 800 in communicationwith robotic arm 460. In FIG. 3 controller 800 is shown as a distinctseparate unit, but in other embodiments it may be incorporated intoeither chamber 300 or chamber 400. Controller 800 may comprise asuitable computer or microcontroller with a memory to store a softwareprogram and data provided by the operator. The operating of robotic arm460 may comprise the operating of rotary stage 470 and the operating ofgrips 462 and 464. In some embodiments, controller 800 may also operatethe sterilization facility not shown in FIG. 3 . Controller 800 may alsocontrol the sealing of chamber 400 and the pressure inside of chamber400. This allows the automation of the processes employed in system2000.

A variety of containers may be disposed within the interior of chamber300. In FIG. 3 the examples given are rigid pharmaceutical containers510 of a first size, rigid pharmaceutical containers 530 of a secondsize, and intravenous (IV) bags 550. As shown in FIG. 3 , a plurality ofcontainers 510 may be aseptically sealed to container mounting plate 570as already described, and container mounting plate 570 may then beaseptically sealed to transfer wall 480. As shown in FIG. 3 , the samearrangement may be made with respect to differently sized rigidcontainers 530 and container mounting plate 590. A plurality of IV-bags550 may be aseptically sealed to container mounting plate 580 as alreadydescribed, and container mounting plate 580 may then be asepticallysealed to transfer wall 480. In an alternative embodiment, thesecontainers 510, 530 and 550 may be aseptically sealed directly totransfer wall 480 in exactly the same way (not shown in FIG. 3 ) as theyare described above to be sealed to transfer wall 280. The use of anarticulated arm 460 allows the linearly arranged containers to be easilyaccessed by syringe 600. Transfer wall 480 may have corresponding holesto allow access by needle 610 to the various containers while an asepticcondition is maintained in the interior of chamber 400.

Robotic rotary arm 460 may position and manipulate syringe 600 in orderto pierce the pierceable closure 512 through hole 521 with hollow needle610. With the needle within the interior volume of container 512, aportion of any fluid in syringe 600 may be injected into container 510,or a portion of any fluid in container 512 may be extracted fromcontainer 510 into syringe 600 for use elsewhere.

To ensure that atmosphere external to chamber 400 cannot leak intochamber 400, chamber 400 is capable of operating under a positivepressure with respect to the environment outside chamber 400. This aidsin ensuring the aseptic condition inside chamber 400. The filter andpump systems required to establish such positive pressure are wellunderstood by those skilled in the art and will not be dwelt upon inthis specification.

In a further aspect described at the hand of the flow chart of FIG. 4 ,a method [3000] is provided for filling pharmaceutical containers with afluid pharmaceutical product. The method [3000] comprises: providing[3100] an aseptically sealable chamber 200, 400 comprising a robotic arm260, 460 and a transfer wall 280, 480 capable of having asepticallymounted thereto a plurality of pharmaceutical containers 510, 530, 550pre-sealed with pierceable closures 512, 554; aseptically mounting[3200] to the transfer wall 280, 480 a plurality of receivingpharmaceutical containers 510, 530, 550 aseptically pre-sealed withcorresponding pierceable closures 512, 554; providing [3300] within thesealable chamber 200, 400 a first pharmaceutical syringe 600 comprisinga first syringe needle 610 and containing a first fluid pharmaceuticalproduct; aseptically sealing [3400] the sealable chamber 200, 400;establishing [3500] an aseptic condition within the interior of thesealable chamber 200, 400 and on all portions of the plurality ofreceiving pharmaceutical containers 510, 530, 550 exposed to theinterior of the sealable chamber 200, 400; piercing [3600] thepierceable closure 512, 554 of at least one of the receiving containers510, 530, 550 with the first syringe needle 610; and injecting [3700] aportion of the product from the first syringe 600 into the at least onereceiving container 510, 530, 550 through the closure 512, 554 via thefirst syringe needle 610. The providing [3100] an aseptically sealablechamber 200, 400 may comprise providing an aseptically sealable chamber200, 400 comprising an articulated robotic arm 260, 460 and theinjecting [3700] may comprise operating the articulated robotic arm 260,460.

The providing [3300] a first syringe 600 within the sealable chamber200, 400 may comprise: aseptically mounting to the transfer wall 280,480 a first source pharmaceutical container containing the first fluidpharmaceutical product and aseptically pre-sealed with a correspondingpierceable closure wherein the mounting of the first source containercomprises disposing the first source container in a location andorientation wherein its associated closure is penetrable from within theinterior of the sealable chamber 200, 400; piercing the associatedclosure with the first syringe needle 610; and extracting a portion ofthe first fluid pharmaceutical product from the first sourcepharmaceutical container into the first pharmaceutical syringe 600.

At least one of the aseptically sealing [3400], the establishing anaseptic condition [3500], the piercing [3600], the injecting [3700], andthe extracting a portion of the first fluid pharmaceutical product isperformed automatically. The method may further comprise establishingwithin the sealable chamber 200, 400 a positive atmospheric pressure andestablishing the pressure may be performed automatically after theaseptically sealing [3400] the sealable chamber 200,400.

The method may further comprise: second injecting a portion of a secondfluid pharmaceutical product from a second syringe into the at least oneof the plurality of receiving pharmaceutical containers through thecorresponding pierceable closure via an associated second syringeneedle. The providing [3100] an aseptically sealable chamber 200, 400may comprise providing an aseptically sealable chamber 200, 400comprising a syringe store 230, 430 and the second injecting maycomprise: aseptically mounting to the transfer wall a second sourcepharmaceutical container aseptically pre-sealed with a correspondingpierceable closure and containing the second fluid pharmaceuticalwherein the mounting of the second source pharmaceutical containercomprises disposing the second source pharmaceutical container in alocation and orientation wherein the second source pharmaceuticalcontainer closure is penetrable from within the interior of the sealablechamber 200, 400; operating the robotic arm 260, 460 to place the firstsyringe in the syringe store 230, 430; operating the robotic arm 260,460 to obtain from the syringe store 230, 430 the second pharmaceuticalsyringe comprising the second syringe needle; operating the robotic arm260, 460 to pierce the closure of the second source pharmaceuticalcontainer with the second syringe needle; and operating the robotic arm260, 460 to extract a portion of the second fluid pharmaceutical productfrom the second source pharmaceutical container into the syringe.

The establishing an aseptic condition may comprise treating the interiorof the sealable chamber 200, 400 and all portions of the at least onereceiving pharmaceutical container exposed to the interior of thesealable chamber 200, 400 with at least one of heated water vapor,gaseous hydrogen peroxide, ozone, nitrogen dioxide, ethylene oxide andglutaraldehyde vapor.

Systems according to the invention can allow a variety of dispensingoperations, including but not limited to pharmaceutical compoundingoperations. Different amounts of an active ingredient can be extractedfrom a source container and added to receiving containers that areprefilled with an inactive ingredient, for example, allowing thedifferent receiving containers to hold different doses of an activeingredient. Different active and/or inactive ingredients can also beextracted from two or more different source containers and added to oneor more receiving containers, allowing more complex formulations.Depending on the selected sequencing for a particular dispensingoperation, the system may need to switch syringes to avoid crosscontamination.

The system described above has been implemented in connection withspecial-purpose software running on a general-purpose computer platform,but the underlying logic could also be embodied in whole or in partusing special-purpose hardware. And while the system can be broken intothe series of modules and steps shown for illustration purposes, one ofordinary skill in the art would recognize that it is also possible tocombine them and/or split them differently to achieve a differentbreakdown, and that the functions of such modules and steps can bearbitrarily distributed and intermingled within different entities, suchas routines, files, and/or machines. Moreover, different providers candevelop and operate different parts of the system.

Embodiments of the present invention addresses the need for compactsmall scale filling and dispensing of fluid pharmaceuticals and confinesonly essential aseptic subsystems to an aseptic chamber, whilst makingit possible to handle aseptically sealed pharmaceutical containers inthe ambient environment outside the aseptic chamber.

While this invention has been described as having an exemplary design,the present invention may be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains.

What is claimed is:
 1. A method for filling pharmaceutical containerswith a fluid pharmaceutical product, the method comprising: providing anaseptically sealable chamber comprising a robotic arm and a transferwall capable of having aseptically mounted thereto a plurality ofpharmaceutical containers pre-sealed with pierceable closures, whereinthe aseptically sealable chamber is capable of maintaining an asepticcondition within an interior of the sealable chamber when thepharmaceutical containers are mounted to the transfer wall, asepticallymounting to the transfer wall a plurality of pharmaceutical containersaseptically pre-sealed with corresponding pierceable pharmaceuticalcontainer closures, wherein the mounting of the plurality ofpharmaceutical containers comprises mounting the plurality ofpharmaceutical containers in locations and orientations wherein thecorresponding pierceable pharmaceutical container closures arepenetrable from within the interior of the sealable chamber, providingwithin the sealable chamber a first pharmaceutical syringe comprising afirst syringe needle, wherein the step of providing an asepticallysealable chamber includes providing a rotary stage upon which therobotic arm is mounted, aseptically sealing the sealable chamber,establishing an aseptic condition within the interior of the sealablechamber and on all portions of the plurality of pharmaceuticalcontainers exposed to the interior of the sealable chamber, andtransferring a portion of the first fluid pharmaceutical product betweenthe first syringe and at least one of the plurality of pharmaceuticalcontainers through the corresponding pierceable pharmaceutical containerclosure via the first syringe needle.
 2. The method of claim 1, whereinthe transferring comprises piercing the corresponding pierceablepharmaceutical container closure with the first syringe needle.
 3. Themethod of claim 1, wherein the transferring comprises operating therobotic arm.
 4. The method of claim 1, wherein providing an asepticallysealable chamber comprising a robotic arm comprises providing anaseptically sealable chamber comprising an articulated robotic arm andthe transferring comprises operating the articulated robotic arm.
 5. Themethod of claim 1, wherein the transferring includes injecting a portionof the first pharmaceutical product into the one of the plurality ofpharmaceutical containers, and wherein providing within the sealablechamber the first pharmaceutical syringe containing the first fluidpharmaceutical product comprises: aseptically mounting to the transferwall a first source pharmaceutical container aseptically pre-sealed witha corresponding pierceable first pharmaceutical container closure,wherein the mounting of the first source pharmaceutical containercomprises disposing the first source pharmaceutical container in alocation and orientation wherein the first pharmaceutical containerclosure is penetrable from within the interior of the sealable chamber,piercing the closure of the first source pharmaceutical container withthe first syringe needle, and extracting a portion of the first fluidpharmaceutical product from the first source pharmaceutical containerinto the first pharmaceutical syringe.
 6. The method of claim 5, whereinat least one of the aseptically sealing, the establishing an asepticcondition, the transferring, and the extracting a portion of the firstfluid pharmaceutical product is performed automatically.
 7. The methodof claim 5, further comprising establishing within the sealable chambera positive atmospheric pressure.
 8. The method of claim 7, wherein theestablishing within the sealable chamber a positive atmospheric pressureis performed automatically after the aseptically sealing the sealablechamber.
 9. The method of claim 5, further comprising injecting aportion of a second fluid pharmaceutical product from a second syringeinto the at least one of the plurality of pharmaceutical containersthrough the corresponding pierceable pharmaceutical container closurevia a second syringe needle.
 10. The method of claim 9, wherein theproviding an aseptically sealable chamber comprises providing anaseptically sealable chamber comprising a syringe store, and wherein thesecond syringe is prepared by: aseptically mounting to the transfer walla second source pharmaceutical container aseptically pre-sealed with acorresponding pierceable second pharmaceutical container closure andcontaining the second fluid pharmaceutical, wherein the mounting of thesecond source pharmaceutical container comprises disposing the secondsource pharmaceutical container in a location and orientation whereinthe second pharmaceutical container closure is penetrable from withinthe interior of the sealable chamber, operating the robotic arm to placethe first syringe in the syringe store, operating the robotic arm toobtain from the syringe store the second pharmaceutical syringecomprising the second syringe needle, operating the robotic arm topierce the closure of the second source pharmaceutical container withthe second syringe needle, and operating the robotic arm to extract aportion of the second fluid pharmaceutical product from the secondsource pharmaceutical container into the syringe.
 11. The method ofclaim 10, wherein the step of operating the robotic arm to obtain fromthe syringe store the second pharmaceutical syringe includes removing acap off the second pharmaceutical syringe.
 12. The method of claim 11,wherein the step of providing an aseptically sealable chamber includesproviding a capping station, and the removing a cap includes operatingthe capping station.
 13. The method of claim 1, wherein the establishingan aseptic condition comprises treating the interior of the sealablechamber and all portions of the at least one pharmaceutical containerexposed to the interior of the sealable chamber with at least one ofheated water vapor, gaseous hydrogen peroxide, ozone, nitrogen dioxide,ethylene oxide, and glutaraldehyde vapor.
 14. The method of claim 1,wherein providing within the sealable chamber a first pharmaceuticalsyringe comprising a first syringe needle includes removing a cap offthe first pharmaceutical syringe.
 15. The method of claim 14, whereinthe step of providing an aseptically sealable chamber includes providinga capping station, and the removing a cap includes operating the cappingstation.
 16. The method of claim 1, wherein the step of providing anaseptically sealable chamber includes providing at least one grip on therobotic arm, the grip structured and arranged for gripping a syringeneedle and for moving a plunger of the syringe needle with respect to acylinder of the syringe needle.
 17. The method of claim 1, wherein thestep of transferring a portion of the first fluid pharmaceutical productincludes operating the rotary stage.
 18. The method of claim 17, whereinthe step of operating the rotary stage includes moving the robotic armat least one of vertically and rotationally.
 19. A system foraseptically filling pharmaceutical containers with pharmaceutical fluid,the system comprising: means for receiving a plurality of containerswhile exposing accessible parts of the containers, means fortransferring pharmaceutical fluid to and from the containers through theaccessible parts of the containers, means for reaching the accessibleparts of the received containers with the means for transferring, meansfor controlling the means for reaching and the means for transferring,means for together isolating the accessible parts of the containers, themeans for reaching, and the means for transferring, wherein the meansfor together isolating includes an aseptically sealable chamber with arotary stage upon which the means for reaching is mounted, and means forsterilizing the accessible parts of the containers, the means forreaching, and the means for transferring.
 20. The system of claim 19,wherein the means for transferring a portion of the first fluidpharmaceutical product is located on the rotary stage.
 21. The system ofclaim 20, wherein the means for reaching is movable at least one ofvertically and rotationally.